Abrasive article including a core and a bonded abrasive body

Abstract

An abrasive article including a core including an organic material and a first bonded abrasive body integrally bonded directly to the core, the first bonded abrasive body having abrasive particles contained within a bond material and the abrasive article having a bonding factor of at least about 60%.

What is claimed is: 
     
         1 . An abrasive article comprising:
 a core comprising an organic material;   a first bonded abrasive body integrally bonded directly to the core, the first bonded abrasive body comprising abrasive particles contained within a bond material; and   a bonding factor of at least about 60%.   
     
     
         2 . The abrasive article of  claim 1 , wherein the first bonded abrasive body is integrally bonded directly to a peripheral surface of the core, and wherein an interface between the first bonded abrasive body and core comprises not greater than about 5% of the adhesive or the cementing compound for the total surface area of the interface. 
     
     
         3 . The abrasive article of  claim 1 , wherein the core comprises a liner overlying at least a portion of the surface defining the opening, wherein the liner overlies essentially the entire surface defining the opening, wherein the liner comprises a material selected from the group consisting of inorganic materials, organic materials, and a combination thereof, wherein the liner comprises a metal or metal alloy. 
     
     
         4 . The abrasive article of  claim 1 , wherein the core comprises a liner overlying at least a portion of the surface defining the opening, wherein the liner has a heat capacity greater than a heat capacity of the material of the core, and wherein the liner has a heat capacity less than a heat capacity of the material of the core. 
     
     
         5 . The abrasive article of  claim 1 , wherein the core consists essentially of the organic material, wherein the organic material comprises a polymer, wherein the organic material comprises a polymeric material selected from the group consisting of an epoxy polymer, a phenoxy polymer, a polyurea, a polyimide, a polycyanate, a polyurethane, a melamine polymer, a polyester, or foamed structures of the same, or any combination thereof. 
     
     
         6 . The abrasive article of  claim 1 , wherein the core comprises a linear coefficient of thermal expansion (CTE) of at least about 15 microns/(m ° C.), and not greater than about 70 microns/(m ° C.). 
     
     
         7 . The abrasive article of  claim 1 , wherein the core comprises a first filler material, a second filler material distinct from the first filler material and a third filler material distinct from the second filler material. 
     
     
         8 . The abrasive article of  claim 7 , wherein the core comprises a ratio (W1/W3) of at least about 30, wherein W1 represents a content of a first filler material within the core in weight percent for a total weigh of the core and W3 represents a content of a third filler material within the core in weight percent for a total weigh of the core. 
     
     
         9 . The abrasive article of  claim 7 , wherein the core comprises a ratio (W1/W2) of at least about 10, wherein W1 represents a content of a first filler material within the core in weight percent for a total weigh of the core and W2 represents a content of a second filler material within the core in weight percent for a total weigh of the core. 
     
     
         10 . The abrasive article of  claim 7 , wherein the core comprises a ratio (W2/W3) of at least about 2, wherein W2 represents a content of a second filler material within the core in weight percent for a total weigh of the core and W3 represents a content of a third filler material within the core in weight percent for a total weigh of the core. 
     
     
         11 . The abrasive article of  claim 7 , wherein the first filler material comprises not greater than about 65 wt % and at least about 55 wt % for a total weight of the core, wherein the second filler material comprises not greater than about 7 wt % and at least about 2 wt % for a total weight of the core, and wherein the third filler material comprises at least about 0.1 wt % and not greater than about 1 wt % for a total weight of the core. 
     
     
         12 . An abrasive article comprising
 a first bonded abrasive body comprising:
 a bond material; and 
 abrasive particles contained within the bond material; and 
   a core comprising an organic material and integrally bonded to the first bonded abrasive body, the core having a monolithic body including a cylindrical shaped defined by a diameter (d), a circumference (C), and a height (h), wherein the height is at least about 3 inches (7.6 cm); and   a bonding factor of at least about 60%.   
     
     
         13 . The abrasive article of  claim 12 , wherein the first bonded abrasive body comprises a filler contained in a bond material, wherein the filler comprises a material selected from the group of materials consisting of zirconia, silica, titania, and a combination thereof. 
     
     
         14 . The abrasive article of  claim 12 , wherein the core comprises a material with a CTE of at least about 25 μm/m° C. 
     
     
         15 . The abrasive article of  claim 12 , wherein the core comprises a linear coefficient of thermal expansion (CTEba) and the bonded abrasive body comprises a linear coefficient of thermal expansion (CTEc), and wherein the core and the bonded abrasive body comprise a difference in the coefficients of thermal expansion (ΔCTE) defined by the equation [(CTEba−CTEc)/CTEba]×100% of not greater than about 30%. 
     
     
         16 . The abrasive article of  claim 12 , wherein the core comprises a first filler material, a second filler material distinct from the first filler material and a third filler material distinct from the second filler material. 
     
     
         17 . The abrasive article of  claim 16 , wherein the core comprises a ratio (W1/W3) of at least about 30, wherein W1 represents a content of a first filler material within the core in weight percent for a total weigh of the core and W3 represents a content of a third filler material within the core in weight percent for a total weigh of the core. 
     
     
         18 . The abrasive article of  claim 16 , wherein the core comprises a ratio (W1/W2) of at least about 10, wherein W1 represents a content of a first filler material within the core in weight percent for a total weigh of the core and W2 represents a content of a second filler material within the core in weight percent for a total weigh of the core. 
     
     
         19 . The abrasive article of  claim 16 , wherein the core comprises a ratio (W2/W3) of at least about 2, wherein W2 represents a content of a second filler material within the core in weight percent for a total weigh of the core and W3 represents a content of a third filler material within the core in weight percent for a total weigh of the core. 
     
     
         20 . The abrasive article of  claim 16 , wherein the first filler material comprises not greater than about 65 wt % and at least about 55 wt % for a total weight of the core, wherein the second filler material comprises not greater than about 7 wt % and at least about 2 wt % for a total weight of the core, and wherein the third filler material comprises at least about 0.1 wt % and not greater than about 1 wt % for a total weight of the core.